EP0974067A1 - Low stress optical waveguide having conformal cladding and fixture for precision optical interconnects - Google Patents
Low stress optical waveguide having conformal cladding and fixture for precision optical interconnectsInfo
- Publication number
- EP0974067A1 EP0974067A1 EP98911926A EP98911926A EP0974067A1 EP 0974067 A1 EP0974067 A1 EP 0974067A1 EP 98911926 A EP98911926 A EP 98911926A EP 98911926 A EP98911926 A EP 98911926A EP 0974067 A1 EP0974067 A1 EP 0974067A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- waveguide
- ofthe
- core
- cladding
- assembly
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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Classifications
-
- G—PHYSICS
- G02—OPTICS
- G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- G02B6/00—Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings
- G02B6/10—Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings of the optical waveguide type
- G02B6/12—Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings of the optical waveguide type of the integrated circuit kind
- G02B6/122—Basic optical elements, e.g. light-guiding paths
- G02B6/1221—Basic optical elements, e.g. light-guiding paths made from organic materials
-
- G—PHYSICS
- G02—OPTICS
- G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- G02B6/00—Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings
- G02B6/24—Coupling light guides
- G02B6/26—Optical coupling means
- G02B6/30—Optical coupling means for use between fibre and thin-film device
Definitions
- Lithographically formed optical waveguides employing polymeric materials having low optical loss, good long term and short term stability, good flexibility and reduced stress or crack induced optical scattering loss are desired.
- the polymeric materials described herein have short term thermal stability at temperatures above 200°C for device integration and packaging, good long term stability at 120°C for long term operation, low absorption and scattering loss at application wavelengths, flexibility to facilitate device designs in different geometry, precisely controllable refractive indexes for mode and numeric aperture control, and compatibility with existing technologies.
- Waveguides having low propagation loss, generally less than 0.1 dB/cm for light of a wavelength in the range of about 780 to about 1550 nm are attained.
- the present invention provides for the precision alignment of a waveguide array with another corresponding waveguide array or light transmitting device or fiber array.
- a structure serves as an optical interconnect between light transmitting devices.
- the device may be a printed waveguide structure which, when fabricated on a flexible substrate may include a flexible ribbon-type interconnect which can be run directly to a connector or to another device.
- the device itself may be laminated to a rigid structure such as a sheet of rigid plastic or glass with the flexible ribbon interconnects allowed to extend beyond the substrate and which can be fed to an optical connector or other interface between devices.
- Figure la shows a cross sectional view of a ribbon of raised rib waveguides having rounded conformal cladding following a Gaussian curve.
- Figure 5 shows two waveguide ribbons attached to two connectors and the two connectors in proximity to each other prior to being attached together.
- the invention provides an optical waveguide assembly which comprises a substrate, and at least one waveguide on the substrate, each said waveguide comprising a substantially transparent, shaped polymeric core having a plurality of edges, which core is attached on and raised from a surface of the substrate on one edge of the core, and a shaped, polymeric, light reflecting cladding attached on and in substantially conforming registration with each other edge of the core such that the cladding has a shape substantially congruent with the shape of the core and wherein the refractive index of the cladding is less than the refractive index of the core.
- the invention also provides a waveguide connector assembly which comprises
- the invention further provides a method for aligning a first waveguide assembly to a second waveguide assembly which comprises
- a waveguide connector comprising a base having a plurality of substantially parallel channels defined by walls cut along a surface of the base and a cover plate on the base over the channels;
- first and second waveguide assemblies each of which comprises a substrate, and at least one waveguide on the substrate, each said waveguide comprising a substantially transparent, shaped polymeric core having a plurality of edges, which core is attached on and raised from a surface of the substrate on one edge of the core, and a shaped, polymeric, light reflecting cladding attached on and in substantially conforming registration with each other edge of the core such that the cladding has a shape substantially congruent with the shape of the core and wherein the refractive index of the cladding is less than the refractive index of the core; (c) positioning the first and second waveguide assemblies on the base such that each waveguide is positioned in one of the channels and contacts the opposing walls of the channel at two or more points, and such that each waveguide on the first waveguide assembly has an end which is aligned with a corresponding end of a waveguide on the second waveguide assembly.
- the invention also provides a method for aligning a waveguide assembly to an optical fiber assembly which comprises (a) providing a waveguide connector comprising a base having a plurality of substantially parallel channels defined by walls cut along a surface of the base and a cover plate on the base over the channels;
- each said waveguide comprising a substantially transparent, shaped polymeric core having a plurality of edges, which core is attached on and raised from a surface of the substrate on one edge of the core, and a shaped, polymeric, light reflecting cladding attached on and in substantially conforming registration with each other edge of the core such that the cladding has a shape substantially congruent with the shape of the core and wherein the refractive index of the cladding is less than the refractive index of the core;
- each waveguide and optical fiber is positioned in one of the channels and contacts the opposing walls of the channel at two or more points, and such that each of the waveguides on the waveguide assembly has an end which is aligned with a corresponding end of an optical fiber on the optical fiber assembly.
- the invention still further provides a method for aligning a first waveguide assembly to a second waveguide assembly which comprises
- first and second waveguide connectors each comprising a base having a plurality of substantially parallel channels defined by walls cut along a surface of the base and a cover plate on the base over the channels;
- first and second waveguide assemblies each of which comprises a substrate, and at least one waveguide on the substrate, each said waveguide comprising a substantially transparent, shaped polymeric core having a plurality of edges, which core is attached on and raised from a surface of the substrate on one edge of the core, and a shaped, polymeric, light reflecting cladding attached on and in substantially conforming registration with each other edge of the core such that the cladding has a shape substantially congruent with the shape of the core and wherein the refractive index of the cladding is less than the refractive index of the core;
- the invention also provides a method for aligning a first waveguide assembly at least one optical fiber, which comprises
- first and second waveguide connectors each comprising a base having a plurality of substantially parallel channels defined by walls cut along a surface of the base and a cover plate on the base over the channels;
- each said waveguide comprising a substantially transparent, shaped polymeric core having a plurality of edges, which core is attached on and raised from a surface of the substrate on one edge of the core, and a shaped, polymeric, light reflecting cladding attached on and in substantially conforming registration with each other edge of the core such that the cladding has a shape substantially congruent with the shape of the core and wherein the refractive index of the cladding is less than the refractive index of the core;
- each optical fiber is positioned in one channel and contacts the walls of the channel at two or more points; and (f) attaching the first waveguide connector to the second waveguide connector such that each waveguide on the waveguide assembly has an end which is in substantially co-linear alignment with a corresponding end of an optical fiber on the optical fiber assembly.
- compositions used to form each of the cladding and core comprise a photopolymerizable compound and a photoinitiator.
- the photopolymerizable compound used to form each of the cladding and core may be a monomer, oligomer or polymer which is an addition polymerizable, nongaseous (boiling temperature above 30°C at normal atmospheric pressure), ethylenically unsaturated compound containing at least one terminal ethylenically unsaturated group, and is capable of forming a high molecular weight polymer by free radical initiated, chain propagating addition polymerization.
- Such compounds are well known in the art.
- at least one of said polymerizable compounds contains at least two ethylenically unsaturated groups.
- the photopolymerizable compounds are chosen such that after exposure they yield the below described Tg and refractive index. Multifunctional acrylate monomers are preferred.
- R 2 For the core, m preferably ranges from 1 to about 6; R 2 is H or CH 3 , and Ri is a linkage of aliphatic, aromatic or aliphatic and aromatic mixed organic molecular segments.
- Ri is an alkylene, alkylene oxide, arylene oxide, aliphatic polyether or polyester moiety and R 2 is H.
- crosslinked polymers and therefore multifunctional acrylate monomers are preferred.
- One feature of the invention is to reduce stress induced scattering optical loss of the final waveguiding device by using flexible, low glass transition temperature (Tg) polymers.
- the cladding and core may be comprised of structurally similar compositions, it is clear that in order for the cladding to have a refractive index which is lower than the refractive index of the core, they must have different chemical compositions for any individual application. In addition, if the chosen substrate has a refractive index which is less than that of the core, then a buffer layer is required and the buffer, as described below, must have a refractive index which is lower than that of the core.
- the photopolymerizable compound is present in each photopolymerizable composition in an amount sufficient to photopolymerize upon exposure to sufficient actinic radiation.
- the amount of the photopolymerizable compound in the composition may vary widely and amounts normally used in photopolymerizable compositions for use in the preparation of photopolymers for use as the light transmissive element of light transmissive devices may be used.
- the amount of photopolymerizable compound is generally used in an amount of from about 35 to about 99.9 % by weight of the composition.
- the photopolymerizable compound is present in the overall composition in an amount of from about 80% to about 99.5% by weight, preferably from about 95 to about 99.5% based on the weight of the overall composition.
- Suitable photoinitiators include aromatic ketones such as benzophenone, acrylated benzophenone, 2-ethylanthraquinone, phenanthraquinone, 2-tert- butylanthraquinone, 1,2-benzanthraquinone, 2,3-benzanthraquinone, 2,3- dichloronaphthoquinone, benzyl dimethyl ketal and other aromatic ketones, e.g.
- Preferred photoinitiators are 1-hydroxy- cyclohexyl-phenyl ketone (Irgacure 184), benzoin, benzoin ethyl ether, benzoin isopropyl ether, benzophenone, benzodimethyl ketal (Irgacure 651), ⁇ , ⁇ -diethyloxy acetophenone, ⁇ , ⁇ -dimethyloxy- -hydroxy acetophenone (Darocur 1173), l-[4-(2-hydroxyethoxy)phenyl]-2-hydroxy-2-methyl- propan-1- one (Darocur 2959), 2-methyl-l-[4-methylthio)phenyl]-2- morpholino-propan-1-one (Irgacure 907), 2-benzyl-2-dimethylamino-l-(4- morpholinophenyl)-butan-l-one (Irgacure 369), poly ⁇ l-[4-(l
- additives may also be added to the photosensitive compositions depending on the purpose and the end use of the light sensitive compositions.
- antioxidants include antioxidants, photostabilizers, volume expanders, fillers such as for example silica, glass spheres and the like, dyes, free radical scavengers, contrast enhancers, nitrones and UV absorbers.
- a film of the photosensitive compositions may be applied in a number of different ways known in the art, such as spin coating, dip coating, slot coating, roller coating, doctor blading, liquid casting or the like.
- the first photosensitive composition is applied at a thickness of from about 1 micron to about 1 mm, preferably from about 5 microns to about 500 microns.
- the second photosensitive composition is applied at a thickness of from at least about 1 micron, preferably at least about 3 microns.
- actinic radiation is directed onto the film in order to delineate the light transmissive region. That is, the position and dimensions of the light transmissive device is determined by the pattern of the actinic radiation upon the surface of the film on the substrate.
- the radiation pattern must be chosen so that the photopolymerizable composition is polymerized in the desired pattern and so that other regions of the film remain unreacted.
- the photopolymer of the invention is conventionally prepared by exposing the polymerizable composition to actinic radiation of the required wavelength and intensity for the required duration.
- the photochemical excitation be carried out with relatively short wavelength (or high energy) radiation so that exposure to radiation normally encountered before processing (e.g., room lights) will not prematurely polymerize the polymerizable material.
- the processing can utilize a multiphoton process initiated by a high intensity source of actinic radiation such as a laser.
- a high intensity source of actinic radiation such as a laser.
- exposure to ultraviolet light 300-400 nm wavelength
- exposure by deep ultraviolet light (190-300 nm wavelength) is useful.
- Convenient sources are high pressure xenon or mercury-xenon arc lamps fitted with appropriate optical filters to select the desired wavelengths for processing.
- short wavelength coherent radiation is useful for the practice of this invention.
- the pattern is then developed to remove the nonimage areas and leave behind the predetermined pattern.
- Any conventional development method can be used, for example, flushing with a solvent for the unirradiated composition.
- solvents include polar solvents, such as alcohols and ketones. The most preferred solvents are acetone, methanol, propanol, tetrahydrofuran and ethyl acetate.
- the next step in obtaining the device of the present invention is the formation of a cladding on the waveguide core.
- the cladding can be any material capable of keeping applied light in the core.
- the cladding is formed by applying a second photosensitive composition onto the surface of the first, imagewise polymerized photosensitive composition and exposed to form a cladding.
- the second photosensitive layer is imagewise exposed in registration with the core pattern and developed in a manner described/ above.
- the latter structure has a cladding which covers the top and sides of the core. It is advantageous since its core exhibits low internal stresses.
- the optical device has a buffer layer applied to the substrate prior to application of the first photosensitive composition.
- the buffer layer comprises a third photosensitive composition which has a similar Tg property as the second photosensitive but need not be the identical composition.
- the third photosensitive composition is applied onto the surface of the substrate and overall, or non-imagewise exposed to actinic radiation.
- the third photosensitive composition comprises the same component parts as the second photosensitive composition.
- the photopolymerizable materials and processing conditions are selected such that the Tg of the polymerized buffer ranges from about 60 °C or less, preferably about 40 °C or less and more preferably about 25 °C or less.
- the first photosensitive composition need not be fully cured, but is only partially polymerized prior to applying the second photosensitive composition.
- Partially polymerized means that some acrylate groups are present after polymerization, i.e., not all acrylates are converted to saturated hydrocarbons. This means that more than 0% but less than 50% of the number of acrylate groups, preferably about 10% or more but less than about 30% of the acrylate groups remain unreacted prior to applying the second photosensitive composition.
- Partial polymerization of the first photosensitive composition layer prior to application of the second photosensitive composition layer allows the two compositions to intermingle at their interface. This intermingling improves adhesion of the two layers.
- any remaining unpolymerized first photosensitive composition and the second photosensitive composition layers are subjected to a hard curing by a blanket or overall exposure to actinic radiation such that they are both substantially fully polymerized.
- the core and cladding composition intermix at their interface and can be mixed in any desired proportions to fine tune the refractive indices of the cladding, core and the overall device and insure good adhesion between the layers by covalent bonding.
- the method of this invention can be used for making a wide variety of optical elements.
- micro-optical elements such as lenses or prisms which can be designed to transmit light in a direction roughly orthogonal to the substrate.
- Such optical element arrays find utility in application to backlights (e.g. for liquid crystal displays), projection systems, front or rear projection screens, dif ⁇ users, collimators, liquid crystal viewing screens, light directing arrays for collimators and lighting fixtures, exit signs, displays, viewing screens, displays for projection systems, and the like.
- backlights e.g. for liquid crystal displays
- projection systems e.g. for liquid crystal displays
- front or rear projection screens dif ⁇ users
- collimators liquid crystal viewing screens
- light directing arrays for collimators and lighting fixtures exit signs, displays, viewing screens, displays for projection systems, and the like.
- exit signs displays, viewing screens, displays for projection systems, and the like.
- the composition of the current invention can be used to enhance the critical aspects of definition and wall smoothness.
- optical elements produced by the instant invention are determined to have an optical loss of about 0.1 or less and preferably about 0.05 or less 600 to 900 nm.
- the polymerized cladding, core and buffer layers have a Gardner index as described by ASTM D 1544-80 of about 3 or less, preferably about 2 or less and more preferably about 1 or less.
- Device testing and modeling suggest a device life time (time for 0.1 dB/cm loss) of more than 10 years at 120°C (operation temperature) and more than 1 hour at 250°C (device packaging temperature), allowing for application of devices applicable in the aerospace and military industries. Flexibility of the materials allows for fabrication of devices with desired bending angles.
- This invention has application in either multimode or single-mode waveguides.
- Single mode waveguides typically have a core ranging from about 1 to about 10 microns in lateral dimension and multimode waveguides typically have a core ranging from about 10 microns to about 1 mm in lateral dimension.
- the cladding is thin, having a thickness which ranges from about 1 micrometer to about 100 micrometers, preferably from about 3 micrometers to about 50 micrometers. More typically single mode waveguides have a cladding ranging from about 3 to about 10 microns while multimode waveguides typically have a cladding ranging from about 10 microns to about 30 microns.
- the thickness of each cladding is not more than the thickness of each core.
- Guides may have any of a number of convenient cross-sectional shapes, such as circular, polygonal, square as seen as element 11 in Figure 1, rectangular, trapezoidal, and rounded such as following a parabolic or Gaussian curve on the top and sides and flat at the bottom where they contact the substrate or buffer as shown as element 11 in Figure la.
- a waveguide assembly is defined to mean an array of optical waveguides formed on a substrate.
- the invention additionally contemplates a connector and method whereby two waveguide assemblies are optically connected or whereby such a waveguide assembly is optically connected to an array of optical fibers.
- a preferred embodiment of the invention is shown in Figure 1 which depicts an optical waveguide assembly or ribbon 4 consisting of four parallel waveguides including a core 1 and a conformal cladding 11 which are raised from a substrate 2 by optional underlying plateaus 3.
- the waveguides are fabricated on or within substrate structure 2.
- a plateau When a plateau is employed, it may be lithographically formed in a manner described above for the formation of the waveguides. In such a case, the waveguide comprising core and cladding is formed on the plateau after the plateau is formed on the substrate. It is preferred that each waveguide be positioned on its own discrete plateau.
- the waveguide is precision aligned with the raised plateau, preferably to a precision within about 10% of the width of the waveguide, more preferably within about 5% and most preferable within about 1%.
- the raised plateau is optically separate from to each of the waveguides by virture of having a lower index of refraction, but is preferably an integral mechanical part of each waveguide itself.
- the plateau When the waveguide is formed on the plateau, the plateau preferably comprises & transparent polymer with an index of refraction which is less than that of the waveguide, such that light traveling within the waveguide remains confined within the waveguide.
- the alignment features of such a waveguide assembly consist of the sides of the plateaus and/or the sides of the cladding conforming to the sides of the core.
- the alignment of the waveguides is critical upon the plateaus and requires that the ribbon be fabricated in a way which assures that the waveguides are well aligned (e.g., centered) on their respective plateaus.
- the alignment of the plateau with the waveguide is preferably less than about 10 microns, and is more preferably less than about 5 microns.
- the primary alignment feature is the cladding
- the difference in thickness between the two sides is preferably less than about 20% of the average core width and more preferably less than about 10% of the average core width.
- the degree of registration of the core and cladding is preferably such that the offset between the lateral center of the core is less than 10% and more preferably less than 5% of the average width of the core. For the purpose of this invention, such a condition is denoted as being in substantially conforming registration.
- the substrate 2 is composed of a flexible material such as a polymer film.
- Suitable polymeric films non-exclusively include those described above. In this case the structure can be flexed and bent as desired to achieve the necessary orientation for interconnection- with another device.
- FIG. 2 An example of the utility of this invention in achieving an accurate alignment for a prospective interconnection is shown in Figure 2.
- a waveguide assembly or ribbon of waveguides 4 is positioned in a connector which includes a grooved micro-machined fixture or bench 6, which together with a slotted cover piece 5 forms a cavity comprising a series of etched grooves 10 into which the waveguide ribbon 4 is inserted.
- the optical bench fixture comprises a base with a series of parallel groves which match the number (>2) and the spacing of the waveguides in the ribbon.
- the optical bench is formed by grooving or notching a rigid or semi-rigid material with precisely placed channels where for multimode applications the perpendicular distance between adjacent channels is held to at least 5 microns within specification and preferable to within 1 micron or less of specification, and for single mode applications is held to at least 1 micron within specification and preferable to within 0.1 micron or less.
- Material from which the optical bench is fabricated can vary widely and can comprise glass, plastics, metals, ceramics, and semiconductors.
- a preferred material is single-crystal silicon. Such a material can be masked and etched by conventional techniques to produce the required precisely placed channels.
- Lateral alignment within the fixture is achieved by contacting the sides of the plateaus and/or the sides of the waveguides with the sloping walls of the etched grooves 10.
- Vertical alignment is achieved by the constraint of the substrate 2 between the bench 6 and the cover plate 5.
- the vertical alignment of the waveguide which is critical, is achieved by controlling the height (thickness) ofthe waveguide core and the plateau with respect to the surface ofthe bench as a reference.
- Lateral alignment is ensured by the waveguide or the plateau having a height and width such that the edge of either or both just touch the wall ofthe groove in the bench. It is preferred that either the plateau or the waveguide be undersized with respect to their width such that only one will serve as the alignment feature.
- the waveguide assembly is positioned in the grooves 10 of bench 6 and then cover plate 5 is attached on top.
- bench 6 and cover plate 5 are pre-bonded or are a single piece monolithic construction and grooves and cover plate slot 9 are milled out, molded, or the like.
- the waveguide assembly is then slid into the grooves 10 and slot 9. It is preferable that the waveguides and the plateaus, if present, are comprised of a flexible material which can deform slightly to conform with the precisely aligned grooves ofthe bench.
- Covers for the optical bench are optionally employed to form a rectangular cross-section channel into which the waveguide ribbon may be inserted.
- Covers may be fabricated from any of a number of rigid materials such as glass, plastics, metals, ceramics, and semiconductors.
- the preferred material for the cover is clear glass, which can be conveniently bonded directly to the silicon optical bench.
- the required channel in the cover depending on the choice of material, can be formed by a variety of techniques such as extruding, molding, embossing, grinding, milling and cutting. When the cover is glass, the preferred method for forming the channel is grinding.
- two waveguide assemblies can be spliced together.
- a first waveguide assembly can be spliced to a second waveguide assembly by closely positioning the ends of each ofthe waveguides on one waveguide assembly to those of corresponding ends ofthe waveguides of another waveguide assembly in the grooves and slot between a single bench and cover.
- the a waveguide assembly can be spliced in a similar fashion to a plurality of optical fibers.
- Figures 2 through 4 show a bench and cover plate both with a waveguide assembly and a series of optical fibers.
- NA numerical aperture
- Conventional multi-mode glass fiber generally possess a numerical aperture (NA) near either 0.22 or 0.29. If n ⁇ is the index of refraction ofthe waveguide core and n 2 is the index ofthe cladding and the buffer, then the NA equals (n n 2 2 ) 1 2 . For a given value of ni the formulations for the cladding and the buffer polymers are adjusted to give a value of n 2 which leads to the desired NA.
- Final assembly ofthe device requires insertion ofthe completed waveguide ribbon into the alignment fixture (optical bench and cover), preferably followed by adhesively bonding the ribbon within the fixture.
- the bonding may be accomplished by providing a "glue hole” through the cover and adding glue through this hole once the ribbon has been inserted.
- the adhesive contacts the substrate and the cover and does not migrate to the waveguide side. It may, in some instances, be advantageous to apply adhesive to the waveguides themselves before insertion.
- a waveguide assembly can be fixed in a bench arid cover and attached to a corresponding second waveguide assembly in a second bench and cover.
- a first waveguide assembly can be fixed within a first bench and cover and a second waveguide assembly or an array of optical fibers can be fixed within a second bench and cover.
- the first and second bench and cover combinations are attached to one another by physically mating the two bench and cover assemblies, such that the waveguide ends are aligned.
- Figure 2 shows a first waveguide assembly fixed within a first bench and cover and an array of optical fibers can be fixed within a second bench and cover.
- the fiber may also have a buffer coating material, for example an acrylic or polyimide.
- the vertical alignment ofthe light conducting waveguides is ensured by the appropriate choice of plateau height.
- the alignment of one optical bench to the other within the connector can be achieved by a variety of means.
- One preferred method is to use pins or rails to engage outer grooves formed by the sloping wall ofthe bench and the bottom surface ofthe top cover ofthe alignment fixture.
- the two connectors may either be permanently mated or may be de-mateable.
- the co-linear (coaxial) alignment ofthe corresponding waveguides and/or fibers in the assembled connector is critical. It is also critical that the end faces ofthe waveguides in the two connector halves be in close proximity when the connector is mated to accomplish this requirement.
- the waveguide ribbon be inserted in its corresponding alignment fixture to a depth such that the end face ofthe waveguide core is flush to the end ofthe alignment element.
- the core and the end face ofthe alignment element for multimode applications are preferably flush to within 10 microns and more preferably flush to within 5 microns, and for single mode applications are flush to within 3 microns and more preferably to within 1 micron. This condition may be accomplished by accurate insertion using visual inspection means, or it may be accomplished by inserting the ribbon so that it protrudes by a small amount, and then cutting or polishing the ribbon back to the level ofthe end face ofthe alignment fixture (the bench and its cover).
- each waveguide is provided with a discrete plateau 3.
- the purpose ofthe discrete plateau structure is to compensate for the thickness ofthe cladding and optional jacketing on a glass or polymer fiber 7 having a round or elliptical cross-section.
- the plateau layer can be eliminated.
- An alternative alignment scheme can also be adopted for a connector designed to interface ribbed polymer waveguides with clad or jacketed glass or polymer fiber.
- either the position ofthe fibers can be adjusted by making the grooves in the optical bench less deep and slotting the cover plate as shown in Figure 3, or the relative alignment ofthe optical benches within the two connector halves can be offset by an amount to compensate for the thickness ofthe fiber as shown in Figure 4.
- This scheme allows for the use of a simpler construction for the ribbed waveguide without need for a discrete plateau, which in turn eliminates a costly manufacturing step.
- lateral alignment is accomplished by the lateral cladding ofthe waveguides contacting the walls ofthe grooves in the bench.
- the monomers or the oligomers were mixed with the photoinitiators and the antioxidant and well stirred.
- the solutions obtained were coated into thin liquid films by spin coating, slot coating or direct liquid casting with appropriate spacers.
- the thickness ofthe film was controlled by spinning speed or spacer thickness.
- the liquid films were placed in a sealed box of controlled atmosphere and photocured with an Oriel mercury xenon lamp (1000W) for 15 seconds in air and then 60 seconds in nitrogen.
- the thickness ofthe films below 50 mm was measured with a Sloan Dektak II A profilometer and the thickness ofthe thicker films were measured with a microscope.
- EBDA ethoxylated bisphenol A diacrylate
- HDDA 1,6-hexanediol diacrylate
- Irgacure 651 0.6 g photoinitiator
- Irganox 1010 was vigorously stirred for 1 h at 60°C to form a homogeneous solution.
- the solution was then
- the sample remained colorless, corresponding to Gardner color index of 1, as described by ASTM D1544- 80, and there were no delamination from the substrate and no cracking in the polymer layer.
- the glass transition temperature measured by dynamic mechanical analysis (DMA) was 40°C.
- DMA dynamic mechanical analysis
- EXAMPLE 3 On a clean glass substrate is coated a layer of photopolymerizable composition given in Example 1. The thickness ofthe layer ranges from about 5 to 500 micrometers in order to form a device which is compatible with conventional glass and plastic optical fibers for low insertion loss.
- the photopolymerizable layer is then exposed to a beam of ultraviolet light using a mercury xenon lamp from Oriel through a photomask, which defines the desired feature and geometry ofthe final waveguiding device.
- the imagewise exposed film is developed with propanol to form a light guiding core structure.
- a second polymerizable composition given in Example 2 having lower refractive index than the core, is coated and blanket exposed to form a cladding layer. Subsequently, the device is baked in a nitrogen purged oven at 120°C for 1 h.
- EXAMPLE 4 The photopolymerizable composition given in Example 2 is spin coated on a polyimide film substrate and blanket exposed to a beam of ultraviolet light to cure the liquid monomer composition into a solid thin film as a buffer layer. The composition given in Example 1 is then coated on top ofthe buffer layer as a core layer. The thickness ofthe core layer ranges from about 5 to 500 micrometers in order to form a device which is compatible with convention glass and plastic optical fibers for low insertion loss. The photopolymerizable core layer is then exposed to a beam of ultraviolet light through a photomask, which defines the desired feature and geometry ofthe final waveguiding device. The imagewise exposed film is developed with propanol to form a light guiding core structure. The polymerizable composition given in Example 2 is coated on top ofthe imaged core layer and blanket exposed to form a cladding layer. Subsequently, the device is baked in a nitrogen purged oven at 120°C for 1 h.
- the photopolymerizable composition given in Example 2 is spin coated on a silicon wafer and blanket exposed to a beam of ultraviolet light to cure the liquid monomer composition into a solid thin film as a buffer layer.
- the composition given in Example 1 is coated on top ofthe buffer layer as a core layer.
- the photopolymerizable core layer is then exposed to a beam of ultraviolet light through a photomask, which defines the desired feature and geometry ofthe final waveguiding device.
- the imagewise exposed film is developed with propanol to form a light guiding core structure.
- Example 2 The polymerizable composition given in Example 2 is coated on top ofthe imaged core layer and exposed to a beam of ultraviolet light through a photomask, which defines the desired geometry ofthe final cladding layer so that it, after developing with propanol, envelopes the core structure. Subsequently, the device is baked in a nitrogen purged oven at 120°C for 1 h.
- EXAMPLE 6 A quantity of alignment fixtures were prepared which consisted of a grooved silicon wafer section (herein referred to as a silicon optical bench, element 6 in Figure 2) and a glass cover plate (element 5 in Figure 2). A roughly rectangular channel with a cross section of about 2 mm by about 0.127 mm was ground into the glass cover plate and the ground side ofthe plate was bonded directly onto the grooved side ofthe silicon bench to from a grooved channel running the full length ofthe piece. The grooves were made deeper along one edge ofthe silicon in order to facilitate the insertion of a waveguide ribbon strip. The dimensions ofthe channel at the other end of the strip are critical to achieving alignment of the light guiding cores ofthe waveguide and were measured to give the results in Table 1.
- a waveguide ribbon was prepared on a 127- ⁇ m thick polyimide film substrate.
- the ribbon consisted of four parallel guides on 400- ⁇ m centers which were centered on four plateaus and over-printed with an aligned cladding structure.
- the guides were produced from a transparent photo- polymerized acrylate polymer.
- the fabrication process required the fabrication of three layers on the polyimide substrate.
- the substrate film was first laminated to a glass slide using a low-adhesive-strength pressure sensitive adhesive (PSA).
- PSA low-adhesive-strength pressure sensitive adhesive
- the first layer was built by exposing an approximately 39-micron-thick layer of monomer through a mask designed to produce the required plateau structure (4 parallel lines of 288- ⁇ m width).
- the second layer was produced from a monomer layer which was approximately 131 ⁇ m thick (measured with respect to the surface ofthe substrate).
- This core layer was produced from a second mask which was precisely aligned with the already printed plateau structure.
- a third layer was produced from a layer of monomer which was 150 ⁇ m thick. This cladding layer was fabricated by exposure through a third mask which was again precisely aligned with the already printed core structure.
- the polyimide film substrate containing the printed structures was then peeled from the glass slide and was cut to an appropriate width (less than 2 mm, the slot width dimension in Example 6) to ensure that the polyimide film edges would not control or interfere with the accurate alignment ofthe ribbon inside the fixture of Example 6.
- the final waveguide ribbon was configured as depicted in Figure 1. Measurement ofthe dimensions ofthe structure with the aid of a microscope gave the following results:
- the last row ofthe table pertains to the offset, in two-dimensional projection, between the geometrical centers ofthe cladding and the waveguide core. This offset was kept sufficiently small to satisfy our requirements for this multimode guide of nominal 92- ⁇ m width.
- EXAMPLE 8 The waveguide ribbon of Example 7 was inserted into the alignment fixture of Example 6. The fit was found to be tight with no observable play. The waveguide core was found to be in the appropriate position with respect to the alignment surfaces ofthe silicon optical bench. It was observed that the ribbon could be removed and re-inserted several times without damage.
Abstract
Description
Claims
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US08/838,342 US5850498A (en) | 1997-04-08 | 1997-04-08 | Low stress optical waveguide having conformal cladding and fixture for precision optical interconnects |
US838342 | 1997-04-08 | ||
PCT/US1998/005613 WO1998045737A1 (en) | 1997-04-08 | 1998-03-23 | Low stress optical waveguide having conformal cladding and fixture for precision optical interconnects |
Publications (2)
Publication Number | Publication Date |
---|---|
EP0974067A1 true EP0974067A1 (en) | 2000-01-26 |
EP0974067B1 EP0974067B1 (en) | 2004-05-26 |
Family
ID=25276860
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP98911926A Expired - Lifetime EP0974067B1 (en) | 1997-04-08 | 1998-03-23 | Low stress optical waveguide having conformal cladding and fixture for precision optical interconnects |
Country Status (8)
Country | Link |
---|---|
US (1) | US5850498A (en) |
EP (1) | EP0974067B1 (en) |
JP (1) | JP4138892B2 (en) |
AT (1) | ATE268011T1 (en) |
CA (1) | CA2286178A1 (en) |
DE (1) | DE69824168T2 (en) |
TW (1) | TW390966B (en) |
WO (1) | WO1998045737A1 (en) |
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-
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- 1998-03-23 AT AT98911926T patent/ATE268011T1/en not_active IP Right Cessation
- 1998-03-23 DE DE69824168T patent/DE69824168T2/en not_active Expired - Lifetime
- 1998-03-23 CA CA002286178A patent/CA2286178A1/en not_active Abandoned
- 1998-03-23 WO PCT/US1998/005613 patent/WO1998045737A1/en active IP Right Grant
- 1998-03-23 EP EP98911926A patent/EP0974067B1/en not_active Expired - Lifetime
- 1998-04-17 TW TW087105281A patent/TW390966B/en active
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Title |
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See references of WO9845737A1 * |
Also Published As
Publication number | Publication date |
---|---|
CA2286178A1 (en) | 1998-10-15 |
WO1998045737A1 (en) | 1998-10-15 |
JP2001519045A (en) | 2001-10-16 |
TW390966B (en) | 2000-05-21 |
EP0974067B1 (en) | 2004-05-26 |
DE69824168D1 (en) | 2004-07-01 |
DE69824168T2 (en) | 2005-06-30 |
ATE268011T1 (en) | 2004-06-15 |
JP4138892B2 (en) | 2008-08-27 |
US5850498A (en) | 1998-12-15 |
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